Methods and systems for manufacturing advanced composite components

ABSTRACT

A fiber placement system for manufacturing composite components includes at least one material storage enclosure including a material spool assembly, a swiveling roller assembly, and a redirect roller assembly, for each tow to be produced per course, at least one material feeding/cutting station configured with a nip roller drive system, and a cutting mechanism, at least one material transfer station configured with an individual, moveable guide tray for each tow to be produced per course, the moveable guide trays respectively being configured with a vacuum system, and at least one layup station comprising a vacuum table/layup surface, and a pick-and-place device equipped with an end-effector.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.14/274,444 filed on May 9, 2014, which claims the benefit of U.S.Provisional Application No. 61/777,370 filed on Mar. 12, 2013, both ofwhich are hereby incorporated by reference in their entirety.

This application is related to U.S. Pat. No. 6,607,626, issued Aug. 19,2003; U.S. Pat. No. 6,939,423, issued Sep. 6, 2005; U.S. Pat. No.7,235,149, issued Jun. 26, 2007; U.S. Pat. No. 8,007,894, issued Aug.30, 2011; U.S. Pat. No. 8,048,253, issued Nov. 1, 2011; U.S. Pat. No.8,168,029, issued May 1, 2012; U.S. patent application Ser. No.13/435,006, filed Mar. 30, 2012; U.S. patent application Ser. No.13/557,621, filed Jul. 25, 2012; and PCT/EP2014/054908, filed Mar. 13,2014, all of which are hereby incorporated by reference in theirentirety.

FIELD OF THE INVENTION

The present invention relates generally to the manufacture of advancedcomposite components. More specifically, the present invents relates tomethods and systems for manufacturing advanced composite components bymeans of an automated fiber placement process, utilizing unidirectionalprepreg composite materials.

BACKGROUND

This section is intended to provide a background or context to theinvention recited in the claims. The description herein may includeconcepts that could be pursued, but are not necessarily ones that havebeen previously conceived or pursued. Therefore, unless otherwiseindicated herein, what is described in this section is not prior art tothe description and claims in this application and is not admitted to beprior art by inclusion in this section.

Conventional fiber placement systems are typically optimized to producevery large and often highly contoured parts that receive little or nopost forming prior to curing. The resulting conventional designconfigurations may present significant disadvantages when used toproduce small, substantially flat part blanks, as explained below:

Minimum Course Length (MCL): Conventional fiber placement systems applyeach course of material to the work surface in a more or less continuousfashion, by feeding the tows from the material spools through a complexfiber delivery path, into the nip point of a roller riding along thework surface. This requires that the mechanisms for cutting each tow tothe required length be located on the dispensing head, as close to thenip roller as possible. The distance between the cutting mechanism andthe nip point at the roller determines the length of the shortest tow(or course) that can be produced and laid. A longer minimum courselength dimension thus increases the amount of scrap to be removed duringthe trimming operation. The minimum course length attainable with theconventional fiber placement configuration may therefore be too long tobe practical for producing very small, flat parts.

Complex Tension Control: Because conventional systems apply each courseof material to the work surface in a more or less continuous fashion,each tow must necessarily travel a significant distance from thematerial spool to the dispensing head, while undergoing the stressesimposed by the repeated bending and twisting required along the path.Because the speed of the tow through the fiber delivery system mustmatch the laydown rate of the material on the work surface, theoperations for feeding and cutting each tow to length are typicallyexecuted on the fly. These conditions mandate the use of a sophisticatedand expensive system for controlling the tension in each individual tow.The costs associated with such a tension control system make aconventional fiber placement system impractical as an alternative tohand layup for producing very small, substantially flat parts.

Contoured Layup Capability: The configuration of conventional fiberplacement systems is driven in part by the need to be able to apply acourse of material to work surfaces having fairly complex contours. Therequirement for such a capability influences the design in a number ofsignificant ways, the net effect of which drives a system design that istoo complex and expensive to be a viable alternative to the hand layupprocess for small, substantially flat parts, for example:

-   -   Conventional systems typically require a dispensing head design        that permits each individual tow to be able to be paid out        individually while at full layup speed, so as to be better able        to conform to the contours of the work surface;    -   Conventional systems typically require a complex nip roller        design with sufficient compliance to accommodate abrupt,        localized changes in contour;    -   Conventional systems typically require a high-powered source of        process heat to tackify the part surface on the fly at full        layup speed; and    -   Conventional systems typically require a relatively large        manipulator with 6 (and in some cases, 7) degrees of freedom in        order to be able to apply a course of material onto the work        surface at the correct orientation and path, with sufficient        mold clearance.

A need exists for improved technology, including technology forefficiently producing advanced composite part blanks, especially small,substantially flat advanced composite part blanks.

SUMMARY

Embodiments provide methods, systems, and devices for manufacturingadvanced composite components by means of an automated fiber placementprocess, utilizing unidirectional prepreg composite materials.Embodiments described herein may provide means for efficiently producingsmall, substantially flat net-shape composite laminates, which may thenbe post formed and cured after layup. Typically, such parts have beenproduced via conventional hand layup methods. In contrast, embodimentsprovide an automated process in a cost-effective manner, to improve theconsistency of part quality, reduce cost, and increase throughput.Embodiments may apply to the efficient manufacture of boththermoset-based and thermoplastic-based composite materials. However,for illustrative purposes, embodiments described in detail herein focuson unidirectional thermoset prepreg composite materials.

One embodiment of the invention relates to a method of manufacturingcomposite components using a fiber placement system, the systemcomprising:

at least one material storage enclosure including a material spoolassembly, a swiveling roller assembly, and a redirect roller assembly,for each tow to be produced per course;

at least one material feeding/cutting station configured with a niproller drive system, and a cutting mechanism;

at least one material transfer station configured with an individual,moveable guide tray for each tow to be produced per course, the moveableguide trays respectively being configured with a vacuum system; and

at least one layup station comprising a vacuum table/layup surface, anda pick-and-place device equipped with an end-effector,

the method comprising the steps of:

activating the nip roller drive system for pulling each lane of materialforward through its respective swiveling rollers and redirect rollers sothat each lane of material is fed forward beyond the cutting mechanismand on into its respective guide tray located in the at least onematerial transfer station;

after each lane having been fed a desired distance into its respectiveguide tray, activating the vacuum system of each respective moveableguide tray, causing each lane of material to be held in position;

after causing each lane of material to be held in position in itsrespective moveable guide tray, actuating the cutting mechanism forsevering each lane of material from the material being fed from thematerial supply spools and thereby creating individual tows;

with each lane of material held in position in its respective moveableguide tray, moving the moveable guide trays horizontally, in thedirection away from cutting mechanism, thereby making all of the towsaccessible by the pick-and-place device;

rotating the end-effector of the pick-and-place device into alignmentwith the moveable guide trays;

lowering the end-effector into contact with the tows;

activating the end-effector;

deactivating the vacuum system in the moveable guide trays;

retracting the end-effector of the pick-and-place device, so as to liftthe tows away from the moveable guide trays;

positioning the end-effector of the pick-and-place device above thevacuum table/layup surface;

lowering the end-effector of the pick-and-place device so as to placethe tows into contact with a previously laid ply on the vacuumtable/layup surface;

deactivating the end-effector of the pick-and-place device; andretracting the end-effector of the pick-and-place device, leaving thetows in position atop the previously laid ply on vacuum table/layupsurface.

Another embodiment of the invention relates to a fiber placement system.The fiber placement system comprises:

at least one material storage enclosure including a material spoolassembly, a swiveling roller assembly, and a redirect roller assembly,for each tow to be produced per course;

at least one material feeding/cutting station configured with a niproller drive system, and a cutting mechanism;

at least one material transfer station configured with an individual,moveable guide tray for each tow to be produced per course, the moveableguide trays respectively being configured with a vacuum system; and

at least one layup station comprising a vacuum table/layup surface, anda pick-and-place device equipped with an end-effector; wherein

the nip roller drive system is adapted to be activated and to pull eachlane of material forward through its respective swiveling rollers andredirect rollers, so that each lane of material may be fed forwardbeyond the cutting mechanism and on into its respective guide traylocated in the at least one material transfer station;

the vacuum system of each respective moveable guide tray is adapted tobe activated, for causing each lane of material to be held in positionwithin its respective moveable guide tray,

the cutting mechanism is adapted to be actuated, for severing each laneof material from the material being fed from the material supply spoolsand thereby creating individual tows,

the moveable guide trays are adapted to be moved horizontally, in thedirection away from cutting mechanism, for making all of the towsaccessible by the pick-and-place device,

the pick-and-place device is adapted to rotate the end-effector intoalignment with the moveable guide trays, lower the end-effector intocontact with the tows, and activate the end-effector,

the vacuum system in the moveable guide trays is adapted to bedeactivated and the pick-and-place device is adapted to retract theend-effector, so as to lift the tows away from the moveable guide trays,

the pick-and-place device is adapted to position the end-effector abovethe vacuum table/layup surface, and to lower the end-effector so as toplace the tows into contact with a previously laid ply on the vacuumtable/layup surface; and

the pick-and-place device is adapted to retract the end-effector,leaving the tows in position atop the previously laid ply on vacuumtable/layup surface.

Additional features, advantages, and embodiments of the presentdisclosure may be set forth from consideration of the following detaileddescription, drawings, and claims. Moreover, it is to be understood thatboth the foregoing summary of the present disclosure and the followingdetailed description are exemplary and intended to provide furtherexplanation without further limiting the scope of the present disclosureclaimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments can be better understood with reference to the followingdrawings and description. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the invention. Moreover, in the figures, likereference numerals designate corresponding parts throughout thedifferent views.

FIG. 1 is a schematic diagram of an exemplary fiber placement cellaccording to an embodiment.

FIG. 2 is a schematic diagram of exemplary components of an exemplarymaterial storage enclosure according to an embodiment.

FIG. 3 is a schematic diagram of an exemplary material feeding/cuttingstation and redirect roller assembly according to an embodiment.

FIG. 4 is a schematic diagram of a detailed view of the exemplarymaterial feeding/cutting station of FIG. 3.

FIG. 5 is a schematic diagram of an exemplary material transfer stationaccording to an embodiment.

FIG. 6A is a schematic diagram of a detailed view of the materialtransfer station of FIG. 5.

FIG. 6B is a schematic diagram of the material transfer station of FIG.6A with the top guide removed for illustration purposes.

FIG. 7 is a schematic diagram of an exemplary layup station according toan embodiment.

FIG. 8 is a schematic diagram illustrating an exemplary operation of asystem for manufacturing an advanced composite component according to anembodiment.

FIG. 9 is a schematic diagram illustrating an exemplary operation of asystem for manufacturing an advanced composite component according to anembodiment.

FIG. 10 is a schematic diagram illustrating an exemplary operation of asystem for manufacturing an advanced composite component according to anembodiment.

FIG. 11 is a schematic diagram illustrating an exemplary operation of asystem for manufacturing an advanced composite component according to anembodiment.

FIG. 12 is a schematic diagram illustrating an exemplary operation of asystem for manufacturing an advanced composite component according to anembodiment.

FIG. 13 is a schematic diagram illustrating an exemplary operation of asystem for manufacturing an advanced composite component according to anembodiment.

FIG. 14 is a schematic diagram illustrating an exemplary operation of asystem for manufacturing an advanced composite component according to anembodiment.

FIG. 15 is a schematic diagram illustrating an exemplary operation of asystem for manufacturing an advanced composite component according to anembodiment.

DETAILED DESCRIPTION

Before turning to the figures, which illustrate the exemplaryembodiments in detail, it should be understood that the presentapplication is not limited to the details or methodology set forth inthe description or illustrated in the figures. It should also beunderstood that the terminology is for the purpose of description onlyand should not be regarded as limiting.

Embodiments provide methods, systems, and devices for manufacturingadvanced composite components by means of an automated fiber placementprocess, utilizing unidirectional prepreg composite materials.

Referring to FIGS. 1-15, in embodiments, a fiber placement cell 1 maycomprise a material storage enclosure 2, a material feeding/cuttingstation 8, a material transfer station 12, and a layup station 16.

A material storage enclosure 2 may have backing film receptacle 3mounted to it. Material storage enclosure 2 may include an individualmaterial spool assembly 4, swiveling roller assembly 5, backing filmguide tube 6, and redirect roller assembly 7, for each tow to beproduced per course. Each material spool assembly 4 may include a chuckdevice for securing the material spool to the support spindle and adevice for controlling the back tension on the material being paid out.Material storage enclosure 2 may be equipped with a refrigeration systemto maintain the material spools at the optimum temperature and humidity.

A material feeding/cutting Station 8 may be configured with a nip rollerdrive system 9, a cutting mechanism 10, and material guide trays 11.

As shown best in FIG. 6A, a material transfer station 12 may beconfigured with an individual, moveable guide tray 13, top guide 14, andindividual servo-controlled linear actuator 15, for each tow to beproduced per course. (Some of the figures, such as FIG. 6B, omit topguide 14 for illustration purposes.) The lateral spacing of moveableguide trays 13 with respect to one another may be equal to approximately2x the width of the material employed in the system. This spacing maycorrespond to the position of every other tow in a given course to belaid up. Moveable guide trays 13 may be configured with vacuum ports forsecuring the material in position.

A layup station 16 may comprise a servo-controlled pick-and-placemechanism 17, a vacuum table/layup surface 18, a heating unit 19, and alinear actuator 20. Pick-and-place mechanism 17 may be equipped with avacuum-operated gripper 21, which may be attached to its tool-mountingflange on its last axis of motion. The vacuum-operated gripper 21 may beconfigured with sufficient compliance to permit it to place materialonto contoured surfaces.

Although the figures disclose embodiments configured to produce 4 towsper course, the number of tows to be produced per course may vary andthus may be configured to best suit the application parameters for theparticular parts to be produced.

In embodiments, an exemplary system for manufacturing small advancedcomposite components operates as follows.

Nip roller drive system 9 may be activated and pull each lane ofmaterial 22 forward through its respective swiveling rollers 5 andredirect rollers 7. Each lane of material 22 may be pulledindependently, so as to vary the length of each individual tow, asdictated by the part layup program.

Simultaneously with each lane of material 22 being pulled forward fromits respective material spool by nip roller drive 9, the backing film 23on each spool of material may be continuously stripped off and drawninto backing film receptacle 3 via backing film guide tube 6. Although avacuum-operated backing film removal system is implied in the figures,the backing film removal operation may also be accomplished by windingthe film onto a passive or powered take-up spindle or via any suitablealternative means.

Simultaneously with each lane of material 22 being pulled forward fromits respective material spool by nip roller drive 9, each lane may befed forward beyond cutting mechanism 10 and on into its respective guidetray 13, located in material transfer Station 8. Each lane may be fedthe appropriate distance into its respective guide tray 13, which maycorrespond to the desired length of the tow, as dictated by the partlayup program. As each lane of material 22 is fed forward into itsrespective guide tray 13, it passes beneath top guide 14, which providesContainment in the vertical direction, as shown, for example, in FIGS.8-9 (top guide 14 not shown for clarity).

After each lane of material has been fed the desired distance into itsrespective guide tray 13, the vacuum system may be activated, causingeach lane of material 22 to be held in position within its respectivemoveable guide tray 13.

With each lane of material 22 securely held in its respective moveableguide tray 13, cutting mechanism 10 may be actuated, severing each laneof material from the material being fed from the material supply spoolsand thereby creating individual tows 24.

With each individual tow 24 securely held in its respective moveableguide tray 13, linear actuators 15 may be activated and move eachmoveable guide tray 13 horizontally, in the direction away from cuttingmechanism 10, as shown, for example, in FIG. 10. Each linear actuator 15may move its respective moveable guide tray 13 independently to adiscrete end position, such that:

All of the tows 24 are accessible by the pick-and-place device 17; and

The ends of each of the tows 24 are aligned in the same end-to-endrelationship to one another as they are designed to be in the part beingproduced.

With all of the tows 24 positioned in the proper relationship to oneanother, pick-and-place device 17 may move into position above moveableguide trays 13 and vacuum-operated gripper 21 may be activated.

In embodiments, for the first ply of material to be laid, the followingoperations may occur:

A carrier sheet may be placed onto the surface of vacuum table/layupsurface 18 and the vacuum system may be activated to hold it inposition;

The surface of the carrier sheet may be tackified in order to prepare itto receive the first ply of material;

The pick-and-place device 17 may rotate vacuum-operated gripper 21 intoalignment with moveable guide trays 13, lower it into contact with tows24 (see, for example, FIG. 11), and activate its vacuum;

The vacuum system in moveable guide trays 13 may be deactivated andpick-and-place device 17 may retract vacuum-operated gripper 21, so asto lift tows 24 away from moveable guide trays 13;

The pick-and-place device 17 may position vacuum-operated gripper 21 inthe proper location and orientation above vacuum table/layup surface 18(see, for example, FIG. 13);

The pick-and-place device 17 may lower vacuum-operated gripper 21 so asto place tows 24 into contact with the carrier sheet on vacuumtable/layup surface 18 (see, for example, FIG. 14);

The pick-and-place device 17 may exert slight downward force to presstows 24 against the carrier sheet on vacuum table/layup surface 18 andvacuum-operated gripper 21 vacuum may be deactivated;

The pick-and-place device 17 may retract vacuum-operated gripper 21,leaving tows 24 in position on vacuum table/layup surface 18; and

The pick-and-place device 17 may continue to lay courses of material inthe manner described above until the first ply of the part has beencompleted.

In embodiments, for subsequent plies of material to be laid, thefollowing operations may occur:

The pick-and-place device 17 may rotate vacuum-operated gripper 21 intoalignment with moveable guide trays 13, lower it into contact with tows24 (see, for example, FIG. 11), and activate its vacuum;

While the pick-and-place device 17 is in position above moveable trays13, linear actuator 20 may be activated and move heater unit 19 intoposition above vacuum table/layup surface 18 (see, for example, FIG.12);

The heater unit 19 may be energized so as to warm and tackify thesurface of the previously laid ply of material on vacuum table/layupsurface 18 (although a hot air heating system is implied in the conceptfigures, the heating operation may be accomplished with an infraredsource or any suitable alternative means);

The vacuum system in moveable guide trays 13 may be deactivated and thepick-and-place device 17 may retract vacuum-operated gripper 21, so asto lift tows 24 away from moveable guide trays 13;

With the surface of the previously laid ply warmed and tackified, linearactuator 20 may once again be activated and retract heater unit 19 awayfrom its previous position above vacuum table/layup surface 18 (see, forexample, FIG. 13);

The pick-and-place device 17 may position vacuum-operated gripper 21 inthe proper location and orientation above vacuum table/layup surface 18;

The pick-and-place device 17 may lower vacuum-operated gripper 21 so asto place tows 24 into contact with the previously laid ply on vacuumtable/layup surface 18;

The pick-and-place device 17 may exert a slight downward force to presstows 24 against the previously laid ply on vacuum table/layup surface18;

The vacuum-operated gripper 21 vacuum may be deactivated and thepick-and-place device 17 may retract it, leaving tows 24 in positionatop the previously laid ply on vacuum table/layup surface 18 (see, forexample, FIG. 15); and

The pick-and-place device 17 may continue to lay subsequent courses ofmaterial in the manner described above until all plies of the part havebeen completed.

In embodiments described above, each course of material laid via theabove methods may comprise every other tow position, i.e., each tow in agiven course may be offset in the lateral direction from the adjacenttows, by a distance equal to the width of a Single tow (see, forexample, FIG. 14). The next course produced may then comprise those towsrequired to fill in the gaps between the tows in the previously laidcourse (see, for example, FIG. 15).

In comparison to conventional fiber placement systems utilizing the samewidth and number of lanes of material, each course produced byembodiments described above may be 2× the width of the course producedby a conventional system; however, the actual net area of materialplaced on the layup surface may be similar or identical.

Alternative Embodiments

Many variants of the embodiments described above are also contemplated.

In one aspect, while embodiments described above may be configured toproduce small parts, the embodiments are not limited to any particularsize. Other embodiments may be configured to fabricate larger parts.

In another aspect, embodiments may use any pick-and-place mechanism. Anindustrial pick-and-place robot may comprise any of a number ofpick-and-place configurations. Embodiments may include any means forremoving tows from the guide trays 13 and locating them on the partbeing fabricated.

In another aspect, embodiments are applicable to any width of tape, andare not limited to narrow tape widths. Embodiments may useconfigurations similar to those disclosed herein to fabricate parts madewith wider tape.

In another aspect, the cutter may be configured to cut the ends of thematerial at an angle or curve in order to parts with less edge waste.

In another aspect, a system may include more than one material storageenclosure 2, material feeding/cutting stations 8, material transferstation 12, layup station 16, or elements therein in order to increasespeed or productivity. For example, a machine may be configured with twomaterial storage enclosures 2 and material feeding/cutting mechanisms 8so that the pick-and-place system 17 may pull material from one systemwhile the other is being fed. Or, each material storage enclosure 2 maybe set up to process different widths of tape so that two widths of tapemay be used within a single part.

In addition, in situations where a part needs to be debulked duringlayup, multiple tooling surfaces may be included so that thepick-and-place device 17 may place material on a second part while afirst part is being debulked.

In another aspect, pick-and-place device 17 may be configured with atool-changer such that the vacuum-operated gripper 21 may be removablefrom the pick-and-place device 17 and other end-effectors may beattached. The attachment system may be, for example, a vacuum chuck.Other end effectors may be specialized vacuum-operated grippers designedto place particular types of courses or to place courses on particularareas of a part, such as an area that does not have a constantthickness. Other end-effectors may include, but are not limited to:

A gripper that removes the part from the tooling surface;

A gripper that places a carrier material onto the tool surface uponwhich the part will be laid up;

A gripper that places inserts or other material as needed by the partdesign (an example of such an insert would be a woven glass fiberisolation ply placed on both outer surfaces of the part);

An inspection system that inspects each ply for quality assurance; and

A debulking frame that may be placed over the part and vacuum applied tocompress the part and remove entrapped air.

In another aspect, instead of laying material directly onto the vacuumtable, a carrier material may be secured to the tooling surface (such asa polymer film) by vacuum or other means. The first ply of the part maybe adhered to this carrier material by any suitable method, such asheat, tackifier, or pressure.

In another aspect, embodiments may produce a non-flat part. Whileembodiments described above use a flat tooling surface, curved parts mayalso be laid up using a gripper 21 that would allow the tape to conformto a non-flat part. A simple curve may involve a compliant grippersurface that may conform to the part shape while compressing the towsonto the tool surface. More complex shapes may use more sophisticatedgrippers that can bend or actuate to reshape the flat tows into thefinal part shape.

In another aspect, embodiments described above may also be applied tothe layup of thermoplastic prepreg composite material. In athermoplastic configuration, material storage enclosure 2 may not haveto be refrigerated and may omit film-backing receptacle 3. Alternateheating methods, such as laser, hot gas, infrared, or ultrasonic heatingmay be used in order to heat the material rapidly to a temperature thatwould allow the plies to adhere together during layup. In addition,rather than heating the surface of the already-laid material in order topromote adhesion to the next course of material, pick-and-place device17 or vacuum-operated gripper 21 may include ultrasonic welders to weldthe course being laid up to the underlying plies. Embodiments ofsuitable welding methods are disclosed in U.S. Pat. No. 8,048,253, whichis herein incorporated by reference in its entirety.

In another aspect, present embodiments for manufacturing small advancedcomposite parts may be combined with other layup methods where a hybridprocess would benefit a specific part geometry. For example, for partsthat have a large length-to-width aspect ratio where the plies whosecourses run parallel to the long edge of the part are much longer thanthe plies whose courses run at an angle to the long edge, the longcourses may be placed by another means. Alternative means may include,but are not limited to, hand placement of pre-cut plies of tape materialfor the long courses, using pick-and-place device 17 to place longstrips with an appropriate vacuum-operated gripper 21, or placing tapewith a traversing head for the long courses.

The present embodiments may lead to several surprising and beneficialresults.

In one aspect, with embodiments configured to place precut tows ratherthan feeding and cutting on the fly, physical space limitations of theplacement of the cutting mechanism may be relaxed, thereby permittingthe system to utilize a very short minimum course length (MCL). Theamount of scrap generated may be minimized, thus offering a viablealternative to the hand layup process for small parts.

In another aspect, with embodiments configured to place precut towsrather than feeding and cutting on the fly, the need for an expensiveand sophisticated tension control system may be eliminated, therebyreducing the cost of a system according to the present embodiments.

In another aspect, with embodiments configured with a stationarymaterial storage enclosure and stationary feeding/cutting station, theneed for a complex and expensive fiber delivery system may beeliminated, along with much of the stress imposed on the material by thebending and twisting associated with such systems.

In another aspect, with embodiments configured with a stationarymaterial storage enclosure and stationary feeding/cutting station, mostof the material path may be contained within a refrigerated enclosure,thereby reducing the tackiness of the material and thus the amount ofresin transfer to the components throughout the system. This may offerthe potential for reduced frequency of periodic cleaning while enhancingthe reliability of a system.

In another aspect, with embodiments configured to place precut tows on aflat layup surface, the size, complexity, and thus cost of a manipulatorappropriate for the system is greatly reduced.

In another aspect, with embodiments configured to place precut tows on aflat layup surface, the need to heat/tackifiy the previously laid plieson the fly may be eliminated. A lower capacity and thus less expensiveheating system may be employed without the need for sophisticatedcontrols.

The foregoing disclosure of the embodiments has been presented forpurposes of illustration and description. It is not intended to beexhaustive or to limit other embodiments to the precise forms disclosed.Many variations and modifications of the embodiments described hereinwill be apparent to one of ordinary skill in the art in light of theabove disclosure. The scope of the embodiments is to be defined only bythe claims, and by their equivalents.

Further, in describing representative embodiments of the presentembodiments, the specification may have presented the method and/orprocess of the present embodiments as a particular sequence of steps.However, to the extent that the method or process does not rely on theparticular order of steps set forth herein, the method or process shouldnot be limited to the particular sequence of steps described. As one ofordinary skill in the art would appreciate, other sequences of steps maybe possible. Therefore, the particular order of the steps set forth inthe specification should not be construed as limitations on the claims.In addition, the claims directed to the method and/or process of thepresent embodiments should not be limited to the performance of theirsteps in the order written, and one skilled in the art can readilyappreciate that the sequences may be varied and still remain within thespirit and scope of the present embodiments.

The construction and arrangements of the system for manufacturingadvanced composite components, as shown in the various exemplaryembodiments, are illustrative only. Although only a few embodiments havebeen described in detail in this disclosure, many modifications arepossible (e.g., variations in sizes, dimensions, structures, shapes andproportions of the various elements, values of parameters, mountingarrangements, use of materials, colors, orientations, image processingand segmentation algorithms, etc.) without materially departing from thenovel teachings and advantages of the subject matter described herein.Some elements shown as integrally formed may be constructed of multipleparts or elements, the position of elements may be reversed or otherwisevaried, and the nature or number of discrete elements or positions maybe altered or varied. The order or sequence of any process, logicalalgorithm, or method steps may be varied or re-sequenced according toalternative embodiments. Other substitutions, modifications, changes andomissions may also be made in the design, operating conditions andarrangement of the various exemplary embodiments without departing fromthe scope of the present invention.

As utilized herein, the terms “approximately,” “about,” “substantially”,and similar terms are intended to have a broad meaning in harmony withthe common and accepted usage by those of ordinary skill in the art towhich the subject matter of this disclosure pertains. It should beunderstood by those of skill in the art who review this disclosure thatthese terms are intended to allow a description of certain featuresdescribed and claimed without restricting the scope of these features tothe precise numerical ranges provided. Accordingly, these terms shouldbe interpreted as indicating that insubstantial or inconsequentialmodifications or alterations of the subject matter described and claimedare considered to be within the scope of the invention as recited in theappended claims.

The terms “coupled,” “connected,” and the like as used herein mean thejoining of two members directly or indirectly to one another. Suchjoining may be stationary (e.g., permanent) or moveable (e.g., removableor releasable). Such joining may be achieved with the two members or thetwo members and any additional intermediate members being integrallyformed as a single unitary body with one another or with the two membersor the two members and any additional intermediate members beingattached to one another.

References herein to the positions of elements (e.g., “top,” “bottom,”“above,” “below,” etc.) are merely used to describe the orientation ofvarious elements in the FIGURES. It should be noted that the orientationof various elements may differ according to other exemplary embodiments,and that such variations are intended to be encompassed by the presentdisclosure.

With respect to the use of substantially any plural and/or singularterms herein, those having skill in the art can translate from theplural to the singular and/or from the singular to the plural as isappropriate to the context and/or application. The varioussingular/plural permutations may be expressly set forth herein for thesake of clarity.

1. A method of manufacturing a plurality of tows per course using afiber placement system comprising at least one material storageenclosure, wherein for each tow to be produced per course, the materialstorage enclosure includes a material spool assembly having a materialwound thereon, a swiveling roller assembly, and a redirect rollerassembly; at least one material feeding/cutting station including acutting mechanism; at least one material transfer station, wherein foreach tow to be produced per course, the material transfer stationincludes a moveable guide tray equipped with a vacuum system; and atleast one layup station including a vacuum table/layup surface, and apick-and-place device equipped with an end-effector, the methodcomprising the steps of: pulling each lane of material forward throughits respective swiveling rollers and redirect rollers so that each laneof material is fed forward beyond the cutting mechanism and on into itsrespective guide tray located in the at least one material transferstation; after each lane having been fed a desired distance into itsrespective guide tray, activating the vacuum system of each respectivemoveable guide tray, causing each lane of material to be held inposition; after causing each lane of material to be held in position inits respective moveable guide tray, actuating the cutting mechanism forsevering each lane of material from the material being fed from thematerial supply spools and thereby creating individual tows; with eachlane of material held in position in its respective moveable guide tray,moving the moveable guide trays horizontally, in a direction away fromcutting mechanism, thereby making all of the tows accessible by thepick-and-place device; rotating the end-effector of the pick-and-placedevice into alignment with the moveable guide trays; lowering theend-effector into contact with the tows; activating the end-effector;deactivating the vacuum system in the moveable guide trays; retractingthe end-effector of the pick-and-place device, so as to lift the towsaway from the moveable guide trays; positioning the end-effector of thepick-and-place device above the vacuum table/layup surface; lowering theend-effector of the pick-and-place device so as to place the tows intocontact with a previously laid ply on the vacuum table/layup surface;deactivating the end-effector of the pick-and-place device; andretracting the end-effector of the pick-and-place device, leaving thetows in position atop the previously laid ply on vacuum table/layupsurface.
 2. The method according to claim 1, wherein the end-effector isa vacuum-operated gripper, and wherein for activating and deactivatingthe end-effector the vacuum is activated and deactivated, respectively.3. The method according to claim 1, wherein after lowering theend-effector of the pick-and-place device so as to place the tows intocontact with the previously laid ply on the vacuum table/layup surface,the pick-and-place exerts a downward force to press the tows against thepreviously laid ply on the vacuum table/layup surface.
 4. The methodaccording to claim 1, wherein each lane of material is pulledindependently from its respective material spool assembly, and each laneof material is fed a distance into its respective guide tray, whichcorresponds to a length of the tow, as dictated by a part layup program.5. The method according to claim 1, wherein the at least one layupstation further comprises a heater unit, and wherein the method furthercomprises the steps of: while the pick-and-place device is in positionabove the moveable trays, moving the heater unit into a position abovethe vacuum table/layup surface, and energizing the heater unit so as towarm and tackify the surface of the previously laid ply of material onthe vacuum table/layup surface; and with the surface of the previouslylaid ply warmed and tackified, retracting the heater unit away from itsposition above the vacuum table/layup surface, prior to positioning thevacuum-operated gripper of the pick-and-place device above the vacuumtable/layup surface.
 6. The method according to claim 1, wherein whenmoving the moveable guide trays horizontally, in the direction away fromcutting mechanism, each moveable guide tray is moved independently to adiscrete end position, so that the ends of each of the tows are alignedin the same end-to-end relationship to one another as they are designedto be in the part being produced.
 7. The method according to claim 1,wherein, for at least one course of material to be laid, each tow isoffset in the lateral direction from the adjacent tows by a distanceequal to the width of a single tow, and wherein gaps between the towsare filled by laying tows in a next course of material to be laid. 8.The method according to claim 1, wherein for a first course of materialto be laid, there are performed the steps: placing a carrier materialonto the surface of the vacuum table/layup surface and activating thevacuum system to hold the carrier in position; tackifying the surface ofthe carrier material in order to prepare it to receive the first ply ofmaterial; rotating the end-effector of the pick-and-place device intoalignment with the moveable guide trays; lowering the end-effector intocontact with the tows, activating the end-effector; deactivating thevacuum system in the moveable guide trays; retracting the end-effectorof the pick-and-place device, so as to lift the tows away from themoveable guide trays; positioning the end-effector of the pick-and-placedevice above the vacuum table/layup surface; lowering the end-effectorof the pick-and-place device so as to place the tows into contact withthe carrier material on the vacuum table/layup surface; deactivating theend-effector of the pick-and-place device; exerting a downward force bythe pick-and-place device to press the tows against the carrier materialon the vacuum table/layup surface; deactivating the end-effector of thepick-and-place device; retracting the end-effector of the pick-and-placedevice, leaving the tows in position atop the carrier material on thevacuum table/layup surface; and repeating the steps until the first plyof the part has been completed. 9.-18. (canceled)
 19. The methodaccording to claim 1, wherein each lane of material is pulledindependently, via a nip roller drive system, from its respectivematerial spool assembly, and each lane of material is fed a distanceinto its respective guide tray, which corresponds to a length of thetow, as dictated by a part layup program.
 20. A method of manufacturinga plurality of tows per course using a fiber placement system comprisingat least one material storage enclosure, wherein for each tow to beproduced per course, the material storage enclosure includes a materialspool assembly having a material wound thereon, a swiveling rollerassembly, and a redirect roller assembly; at least one materialfeeding/cutting station including a cutting mechanism; at least onematerial transfer station, wherein for each tow to be produced percourse, the material transfer station includes a moveable guide trayequipped with a vacuum system; and at least one layup station includinga vacuum table/layup surface, and a pick-and-place device equipped withan end-effector, the method comprising the steps of: independentlypulling the material wound on each material spool assembly forwardthrough its respective swiveling roller assembly and redirect rollerassembly, so that the material wound on each material spool assembly isfed forward beyond the cutting mechanism into its respective moveableguide tray located in the material transfer station; after the materialwound on each material spool assembly is fed a desired distance into itsrespective moveable guide tray, activating the vacuum system of eachrespective moveable guide tray, causing the material to be held inposition in its respective moveable guide tray; after causing thematerial to be held in position in its respective moveable guide tray,actuating the cutting mechanism to sever the material from itsrespective material spool assembly, thereby creating one of theplurality of tows; with the material held in position in its respectivemoveable guide tray, moving the moveable guide trays horizontally, in adirection away from the cutting mechanism, thereby making all of theplurality of tows accessible by the pick-and-place device; rotating theend-effector of the pick-and-place device into alignment with themoveable guide trays; lowering the end-effector into contact with theplurality of tows; activating the end-effector; deactivating each vacuumsystem of each moveable guide tray; retracting the end-effector of thepick-and-place device, so as to lift the plurality of tows away from themoveable guide trays; positioning the end-effector of the pick-and-placedevice above the vacuum table/layup surface; lowering the end-effectorof the pick-and-place device so as to place the plurality of tows intocontact with the previously laid ply on the vacuum table/layup surface;deactivating the end-effector of the pick-and-place device; andretracting the end-effector of the pick-and-place device, leaving theplurality of tows in position atop the previously laid ply on vacuumtable/layup surface.